TPM Self-Assessment by Operational Excellence Consulting

© Operational Excellence Consulting. All rights reserved.
TPM Self-assessment
Guidebook & Tool
This package helps you to conduct a systematic TPM self-assessment
based on the JIPM standard and identify areas for improvement. It also
provides a means to establish a baseline for your organization so that
you can measure its progress over time.

© Operational Excellence Consulting. All rights reserved. 2
Objectives
By the end of this self-assessment program,
you will be able to:
• Understand the TPM framework based on the JIPM
standard for world-class manufacturing excellence
• Define the TPM Criteria and Evaluation Areas
• Describe the Point Values and Scoring Guidelines
• Conduct a systematic TPM self-assessment and identify
areas for improvement
• Establish a baseline position so you can measure your
progress over time
NOTE: This is a PARTIAL PREVIEW. To
download the complete guide and tool,
please visit: http://www.oeconsulting.com.sg

Contents
1. Overview of the TPM Excellence Model
2. Criteria for TPM Excellence
3. Award Criteria Guidance Points
4. Scoring Guidelines
5. TPM Self-assessment
6. Post TPM Self-assessment

Overview of the TPM
Excellence Model
1

About JIPM
• Established in 1969
• Non-profit organization
• Provides services to factory/plant management,
plant engineers and maintenance managers
• Develops and promotes total productive
maintenance (TPM)
• Originator of TPM since 1971
Overview of TPM Excellence Model
Note: JIPM = Japan Institute of Plant Maintenance

Objectives of JIPM
• Research and development in production technologies
• Collect and disseminate information and materials about
production technologies
• Certify skills for production activities
• Exchange information with various organizations, both in
Japan and abroad, regarding TPM technologies
• Present awards for achievement in TPM technology

What is the Purpose of the TPM
Excellence Award?
• Promote the modernization
of plant maintenance
• Develop plant maintenance
technologies
• Help to develop Japan’s
competitiveness

Benefits of Applying for TPM
Recognition
• Create enthusiasm for improvement
• Instill a culture of excellence
• Receive a blue print of your results
• Independent self-assessment
• Improve your competitiveness
• International visibility and recognition

How is an Organization Selected as a
TPM Winner?
• Evaluation is based on how the organization is
run (approach and deployment) and on the
basis of performance (results)
 Self-assessment Criteria
 Self-assessment Checklist (10 key areas)
• Every major part of the organization is assessed
• Strong commitment to continuous improvement

TPM Award Categories

Criteria for TPM Excellence
2

TPM Excellence Model
TPMintheOffice
Safety,Health&Environment
AutonomousMaintenance
PlannedMaintenance
FocusedImprovement
EarlyEquipment
Management
QualityMaintenance
Education&Training
5S & Visual Management
TPM
Policies & Objectives

Assessment Criteria (“Basic Conditions”)
1. Formulation of policy and target
2. Formulation of master plan
3. Establishment of promotion
system by top management
4. Manager and technical staff-led
type formation of overlapping
small groups
5. Creation of opportunity for all
members to participate
6. Introduction of step-by-step
implementation system
7. Implementation of step-by-step
examination
8. Ensuring of top management
diagnosis function
9. Establishment of pillars of TPM
implementation
10.Clarification of loss
11.Utilization of methods and
techniques to solve problems/
issues
12.Utilization of tools for circle
Activation
13.Establishment of system for
developing human resources

10 Assessment Areas
1. TPM Policies and
Objectives
2. Individual Improvement
3. Autonomous
Maintenance
4. Planned Maintenance
5. Quality Maintenance
6. Product & Equipment
Development & Control
7. Training and
Development
8. Administrative &
Supervisory
Departments
9. Safety, Sanitation, &
Environmental Control
10.Effects and Evaluation
of TPM
Note: Items 2 to 9 are equivalent to the eight TPM pillars

Three Integrated Components
Approach
Deployment
Results

Approach
• “Approach” refers to how the organization addresses the
criteria requirements in terms of the methods, tools and
techniques used. The factors used to evaluate approach
include the following:
 Extent to which methods, tools and techniques are appropriate for the
requirements.
 Extent to which methods, tools and techniques are effective.
 Degree to which the approach:
 is systematic, integrated and consistently applied; and
 is based upon information that is objective and reliable.
 Evidence of innovation, including significant and effective adaptations of
approaches used in other applications or types of business.

Deployment
• “Deployment” refers to the extent to which the
organization’s approach is applied, implemented and
deployed within and outside the organization. The
factors used to evaluate deployment include the
following:
 Appropriate and effective use of the approach in key operational
areas.
 Appropriate and effective use of the approach in interactions with
customers, employees, suppliers/partners of goods and services
and the public.

Results
• “Results” refers to the outcomes achieved by the
organization. The factors used to evaluate results
include the following:
 Current performance levels
 Performance levels relative to appropriate comparisons and/or
benchmarks
 Rate, breadth and importance of performance improvements
 Linkages of results measures to key performance requirements
identified in the Organizational Profile and Approach/Deployment
criteria items

Award Criteria Guidance
Points
3

Guidance Points for the 10 Areas of Evaluation
Award Criteria Guidance Points

Guidance Points for each Checklist Item
• There are 10 categories or evaluation areas. Although
an equal weightage system is used in this self-
assessment tool, users are free to vary the weightage as
they deem appropriate.
• Each category or evaluation area has 10 checklist items.
Award Criteria Guidance Points
APPROACH NONE REACTIVE DEFINED INTEGRATED REFINED INNOVATIVE
DEPLOYMENT NONE SOME SOME KEY MOST KEY ALL KEY ALL
RESULTS NONE INCONSISTENT POSITIVE MET TARGET
EXCEEDED
TARGET
EXCEPTIONAL
POINTS 0 2 4 6 8 10

Scoring Guidelines
4

Scoring Guidelines
Scoring Guidelines
EXCEEDED
TARGET EXCEPTIONAL
TPM Policies and
Objectives
Individual
Improvement
Autonomous
Maintenance
Planned
Maintenance
Quality
Maintenance
Product &
Equipment Devt &
Control
Training and
Development
Administrative &
Supervisory
Departments
Safety, Sanitation,
& Environmental
Control
Effects and
Evaluation of TPM
BAND 1 2 3 4 5 6
SCORE 0 1 - 199 200 - 399 400 – 599 600 – 799 800 - 1000
Three dimensions
of evaluation
Ten areas of
assessment
Six scoring bands

Scoring Guidelines – Bands 1, 2 & 3
Scoring Guidelines
Score Band Approach Deployment Results
0 1
There is no approach at
all.
There is no deployment.
There are no results, or
results show no
improvement trends and
have not met targets.
1-199 2
Some form of approach
exists but it is reactive and
not systematic.
Approach is deployed to
few areas of the
organization.
Poor results.
Improvement trends
and/or good performance
levels for a few key
indicators.
Results not reported for
most key indicators.
200-399 3
Direction for approach is
defined.
Beginning of a planned
and prevention-based
approach.
some key areas of the
organization.
Improvement trends
and/or good performance
levels for some key
indicators.
Early stages of obtaining
comparative information.
Results reported for some
key indicators.

Scoring Guidelines – Bands 4 & 5
Scoring Guidelines
400-599 4
A sound, effective
approach is in place with
evidence of prevention
activities.
Approach is aligned with
basic organizational needs
identified in other criteria
categories.
most key areas of the
organization.
Improvement trends
and/or current
performance levels are
good for most key
indicators.
Favourable comparisons
and/ or benchmarks in
some areas.
Results reported for most
key indicators.
600-799 5
A proven and well-defined
approach with evidence of
refinement through
learning and improvement.
Approach is well-
integrated with
organizational needs
categories.
all key areas of the
organization.
Practised consistently by
all levels.
Current performance
levels are good to
excellent for most key
indicators.
Improvement trends are
sustained in most areas.
Favourable comparisons
and/or benchmarks in key
areas.
Results reported for all key
indicators.

Scoring Guidelines – Band 6
Scoring Guidelines
800-1000 6
Exceptionally well-defined,
innovative approach.
Approach is accepted as
best practice in the field.
Approach is fully
integrated with
organizational needs
categories.
all areas within and
outside the organization.
Practised consistently by
all levels.
Current performance
levels are excellent for
most key indicators.
Exceptional improvement
trends in most areas.
Exceptional comparisons
and/or benchmarks in
most areas.
Results reported for all
indicators.

Anatomy of Self-assessment Checklist
APPROACH
NONE
REACTIVE
DEFINED
INTEGRATED
REFINED
INNOVATIVE
DEPLOYMENT
NONE
SOME
SOMEKEY
MOSTKEY
ALLKEY
ALL
BAND 1 2 3 4 5 6
1 TPM POLICIES & OBJECTIVES
1 TPM policies are planned in relation between company policies
and plant/factory policy. 0 2 4 6 8 10
2 The relation between TPM target values and management target
results are clear. 0 2 4 6 8 10
3 The master plan is in an appropriate order as an action plan to
achieve TPM. 0 2 4 6 8 10
4 TPM policies and objectives are checked using methods such as
benchmarking that all sections of PQCDSME are displayed
corresponding to 8 pillars.
0 2 4 6 8 10
5 TPM policies and objectives have been set forth and observed by
all the departments and sections. 0 2 4 6 8 10
6 The achievement status of TPM policies and objectives is
available in a time line using objective data. 0 2 4 6 8 10
7 Overlapping small groups, the TPM promotion committee, and
other special committees are organized in a way that leads to
TPM activities.
0 2 4 6 8 10
8 TPM promotion units help facilitate TPM activities within
departments/ sections. 0 2 4 6 8 10
9 Small groups on the front line have been vitalized.
0 2 4 6 8 10
10 The achievement status of TPM objectives is confirmed and
necessary actions are taken for unachieved indexes. 0 2 4 6 8 10
Evaluation
Dimensions
Checklist
Items
Six Bands of
Evaluation
(see Scoring
Guidelines)
Points
Distribution
Assessment
Area
Scoring Guidelines
Each category carries
a maximum of 100
points

How to Conduct the Self-assessment
1. The self-assessment tool comprises of statements that
address specific criteria requirements of a TPM
standard.
2. There are two types of statements in the self-
assessment tool. These are statements that address
the approach and deployment dimensions together
and statements that address the results dimension.
3. The statements are to be rated on a scale of 1 to 6
based on the scoring guidelines. The rating for each
statement is to be written down next to each statement.
Scoring Guidelines

Guidelines on Using the Self-Assessment
Tool
1. A copy of the self-assessment tool should be given to
each member of the self-assessment team(s).
2. The self-assessment team(s) will need to convene one
or more planning session(s) to decide on the
procedures and schedule for carrying out the self-
assessment exercise.
3. They will need to review the self-assessment tool to
identify the basic information that needs to be gathered
to facilitate the process of self-assessment.
Scoring Guidelines

Scoring Each Category and Item
1. For each of the 10 categories,
go through each statement
and give a score which is
reflective of the approach and
deployment status. Do the
same for the results
dimension.
2. Add up all the item scores to
get the total score for the
category. In this example, the
total score for Category 1 =
6+4+4+2+4+4+6+4+4+4 = 42
which is closest to Band 3.
3. Do the same for categories 2
to 10.
Scoring Guidelines
Score 42
APPROACH
NONE
REACTIVE
DEFINED
INTEGRATED
REFINED
INNOVATIVE
DEPLOYMENT
NONE
SOME
SOMEKEY
MOSTKEY
ALLKEY
ALL
BAND 1 2 3 4 5 6
1 TPM POLICIES & OBJECTIVES
1 TPM policies are planned in relation between company policies
and plant/factory policy. 0 2 4 6 8 10
2 The relation between TPM target values and management target
results are clear. 0 2 4 6 8 10
3 The master plan is in an appropriate order as an action plan to
achieve TPM. 0 2 4 6 8 10
4 TPM policies and objectives are checked using methods such as
benchmarking that all sections of PQCDSME are displayed
corresponding to 8 pillars.
0 2 4 6 8 10
5 TPM policies and objectives have been set forth and observed by
all the departments and sections. 0 2 4 6 8 10
6 The achievement status of TPM policies and objectives is
available in a time line using objective data. 0 2 4 6 8 10
7 Overlapping small groups, the TPM promotion committee, and
other special committees are organized in a way that leads to
TPM activities.
0 2 4 6 8 10
8 TPM promotion units help facilitate TPM activities within
departments/ sections. 0 2 4 6 8 10
9 Small groups on the front line have been vitalized.
0 2 4 6 8 10
10 The achievement status of TPM objectives is confirmed and
necessary actions are taken for unachieved indexes. 0 2 4 6 8 10

EXCEEDED
TARGET
EXCEPTIONAL
TPM Policies and
Objectives
Individual
Improvement
Autonomous
Maintenance
Planned
Maintenance
Quality
Maintenance
Product &
Equipment Devt &
Control
Training and
Development
Administrative &
Supervisory
Departments
Safety, Sanitation,
& Environmental
Control
Effects and
Evaluation of TPM
BAND 1 2 3 4 5 6
SCORE 0 1 - 199 200 - 399 400 – 599 600 – 799 800 - 1000
ACTUAL SCORE
Scoring Each Category and Item
4. Next, on the Overall Score
page, shade Category 1 –
‘TPM Policies & Objectives’
under Band 3.
5. Do the same for the other
categories.
6. Finally, add up all the
category scores to obtain the
Overall Band and Overall
Score to compute the result
for the organization.
Scoring Guidelines

Writing the Strengths & Areas for
Improvement
• For each category of self-assessment, write down the
strengths and areas for improvement. The strengths
identified should relate to the top 2-3 scoring
statements. Similarly, the areas for improvement
identified should be related to the lowest 2-3 scoring
statements.
• As a benchmark, in order to be ready for the TPM
Excellence Award (Consistent TPM Commitment,
Category A & Category B), you should aim to achieve at
least 700 points or Band 5 for the organization or 70%
of the points for each category.
Scoring Guidelines

TPM Self-assessment
5

Role of Self-Assessment Team
• The self-assessment team should comprise six to eight
members, who represent key staff in the organization.
• Alternatively, the organization could form different
assessment groups to examine the different criteria
categories in the self-assessment tool.
• The self-assessment teams should examine all areas
based on the assessment criteria.
• All team members should have a good understanding of
the assessment criteria.
TPM Self-assessment

Engage
Management
Team
The Self-assessment Cycle
TPM Self-assessment
Plan the Self-
assessment
Train the
Participants
Conduct the
Self-
assessment
Agree
Priorities
Develop Action
Plans
Monitor
Progress

Post TPM Self-assessment
6

Follow-up Actions
• Receive Feedback Report
• Study Strengths and Areas for Improvement
• Draw up Action Plans to address Areas for
Improvement
• Continue to consolidate Strengths
• Set targets to achieve key milestones
Post TPM Self-assessment

About
Operational
Excellence Consulting

About Operational Excellence
Consulting
• Operational Excellence Consulting is a management
training and consulting firm that assists organizations in
improving business performance and effectiveness.
• The firm’s mission is to create business value for
organizations through innovative operational excellence
management training and consulting solutions.
• OEC takes a unique “beyond the tools” approach to enable
clients develop internal capabilities and cultural
transformation to achieve sustainable world-class excellence
and competitive advantage. For more information, please visit
www.oeconsulting.com.sg

www.oeconsulting.com.sg
END OF PARTIAL PREVIEW
To download this complete self-assessment
guidebook and tool, please visit:

TPM Self-Assessment by Operational Excellence Consulting

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TPM Self-Assessment by Operational Excellence Consulting